3.1. Create a Biomass Pellet Supply Chain Diagram
As mentioned in the methodology section, Nan province was selected as the demonstration province for the development of the corn pellet supply chain diagram due to three commercial biomass pellet manufacturers that export to the international market being located in the province. This made it convenient to gather data and ensure the research covers the entire process. A data collection survey form was developed and disseminated among the Na Noi Agriculture Cooperative members in Nan province of Thailand to obtain insights into their corn farming practices. Of these, fifty-five corn farmers returned the completed surveys and agreed to partake in a follow-up interview session. This session was split into two separate occasions. Detailed interviews were conducted with fifty-five corn farmers and two officials from the Office of Agricultural Economics in Nan province to delve into their corn cultivation methods, operational practices, and data. Based on input information from the interview, the process of corn cultivation begins with the preparation of the planting areas, where corn farmers enlist agricultural services for groundwork. Once the land is ready, corn seeds are sown. Early growth is enhanced, and the application of fertilizers and pesticides controls weeds. About four months are typically required for corn to mature. The harvesting of the crop is usually completed over a span of four to five days, with the collection of the corn ears from each field requiring at least three individuals. Once harvested, the corn ears are then transported to a sorting facility while others clear the farm area and prepare it for the next planting cycle. In the sorting facility, the corn is separated into two main products: corn seeds (88%) and corncobs (12%). These products are subsequently transported to a drying system to reduce their moisture content before storage. When the in-house raw materials are found to be insufficient to maintain production capacity, plant owners import additional corn ears from other regions.
The canning and preserving industry is usually where corn seed is consumed. The manufacture of biomass pellets is typically where most corncobs are utilized, with the remainder being consumed by the animal food industry. The allocation of corncobs between pellet plants and the animal feed industry is not fixed and depends on the purchase prices offered by buyers. Therefore, this research assumed that all corncobs are used as raw materials for the palletization of corn. The corncob is subjected to chopping and grinding systems at the pellet manufacturing stage to reduce its size. The fine particulate is then conveyed to the pelletizing system. The temperature of the product in this process varies from 100 to 120 °C. The product is introduced into a cooling system to reduce its temperature before being transferred to the packaging system.
For the wood pellet production process, fast-growing trees (Leucaena and Acacia) are used as raw materials by the first four plants for producing wood pellets, while the remaining four plants utilize waste wood from the Para rubber wood industry as raw materials. Wood pellet production is interconnected with three main aspects: tree plantation, the wood industry, and pelletizing. The tree plantation process comprises five steps, starting with soil preparation and monitoring of the initial step in wood plantation. Sprouts are needed as raw materials for tree planting, alongside fertilizers and pesticides for tree growth and weed removal. Diesel is consumed in transportation and operating agricultural machinery. Electricity is consumed in self-storage and small warehouses. A seven-year-old Para rubber tree can produce Para rubber latex, and these trees are typically felled when they reach twenty-five to thirty years of age. Para rubber logs are usually sent to Para rubber wood factories to be transformed into plywood. In comparison, fast-growing trees (FGTs) have a shorter life cycle, ranging from five to fifteen years. The production of wood pellets comprises six stages: treatment of raw materials, drying system, comminution system, pelletization, cooling, and packaging and storage. The demand for workers is determined by the scale of the plant. For example, the operation of a plant with an annual production capacity of 7840 tons requires five workers to manage.
3.2. Analysis of Input and Output Data
The annual production of the three pellet manufacturers is 55,125 tons. To achieve this production capacity, approximately 73,500 tons of corncobs are required annually. Consequently, the supply of corncobs necessitates approximately 612,500 tons of ears of corn. When considering the potential of Nan province to supply ears of corn to the manufacturers, according to the latest statistics published by the Office of Agricultural Economics, it was 388,937 tons in 2021. This implies that the biomass potential in the province is only 93,345 tons per year (using a residue-to-product ratio of 0.24 tons of residue per ton of corn to calculate the residual biomass from the total amount of corn). Therefore, 519,155 tons of ears of corn are needed from the nearest provinces to meet the production demand. Biomass potential in the northern part of Thailand in 2021 is depicted in
Figure 4.
The same proportions of material consumption, energy usage in corn plantation and cultivation processes, and operating conditions observed in Nan province were applied to other provinces in the northern part of Thailand to achieve the total demand of 612,500 tons of ears of corn. The Thailand Alternative Power Development Plan 2015 [
33] forecasted biomass demand for heat generation in 2036 to be 22,100 ktoe. Considering the biomass potential of the northern part of Thailand, the average growth rate from 2018 to 2021 was −1.34%. If the biomass production potential in this region continues to decline at this rate from 2021 to 2036, the accumulated biomass generation will be approximately 5286 ktoe. These figures indicate that the provinces located in the northern part of Thailand could be a significant supplier of biomass from agricultural residue for Thailand’s energy needs. Thus, the input and output quantities discussed in the following sections are related to the production of 55,125 tons of corn pellets.
To generate an annual output of 55,125 tons of corn pellets, the corn cultivation process needs to produce approximately 612,500 tons of ears of corn annually. This requires 3810 tons of corn seed as input material for growing corn, followed by 24,500 tons of fertilizer and 4.49 L of diesel per ton of corn for agricultural machinery. All ears of corn produced from the corn cultivation process are transported to the sorting plant. The sorting process requires 12,000 MWh of electricity to operate the sorting system. The 73,500 tons of corncobs sorted by the system are then conveyed to the pellet manufacturing plant.
Table 3 provides a resource breakdown per ton of corn pellets produced. Within the corn cultivation process, it is necessary to use 0.01 tons of corn seed, 0.04 tons of fertilizer, and 7.33 L of diesel to produce one ton of ears of corn. The corn sorting process then takes these ears and, through the use of 0.02 MWh of electricity, sorts them into 0.88 tons of corn seed and 0.12 tons of corncob. Moving to the pelletizing phase, 1.33 tons of corncob are transformed into one ton of corn pellets, utilizing an additional 0.22 MWh of electricity, with no significant by-products. This systematic enumeration of inputs and outputs illustrates the resource efficiency across each stage of production.
Referring to input data derived from the sorting plant, the price of an ear of corn is THB 10 per kg (average annual exchange rate for 2023 was USD/THB 34.77) of product (THB 10,000 per ton of ear of corn). Therefore, the total value of the ear of corn in this research is 6125 mTHB. The average price of corncob sold to the pellet plant is THB 3 per kg of product (THB 3000 per ton of corncob), while the average price of corn seed sold to the animal feed industry is THB 11.50 per kg of product (THB 11,500 per ton of corn seed). The total economic value is calculated at THB 10,480. Of this amount, the economic value attributed to corn seeds is THB 10,120, comprising 96.6% of the total, while the economic value derived from corncobs amounts to THB 360, accounting for 3.4% of the total value. The cost of producing one ton of product is shown in
Table 4, which presents a cost analysis for the production of corn-related products, segmented into the corn cultivation, corn sorting, and pelletizing stages. The costs of the corn cultivation process are broken down as follows: corn seed at THB 1026, fertilizer at THB 448, diesel at THB 256, and labor at THB 634, with the output, a ton of ears of corn, being valued at THB 10,000. The corn sorting process is characterized by the ear of corn, valued at THB 10,000, being processed with additional electricity and labor costs at THB 81.21 and 3, respectively, which yields corn seed and corncob valued at THB 11,500 and 3000, respectively.
For the pelletizing phase, corncob valued at THB 3000 is utilized, and when combined with the costs of electricity (THB 71) and labor (THB 79), corn pellets valued at THB 4200 are produced. The value addition at each phase of production is elucidated by this delineation of costs, tracing the financial transformation from initial inputs to the final product in a passive structure.
From an environmental perspective, the production of corn pellets emits 95.38 MtCO
2e of GHG emissions.
Table 5 presents the GHG emissions from the production of 55,125 tons of corn pellets. In the corn plantation process, GHG emissions are calculated based on activity data for consumption of fertilizer, diesel, and corn seed with their respective emission factors, resulting in 39.01 MtCO
2e for fertilizer, 0.76 MtCO
2e for diesel, and the lowest emissions of 1.08 MtCO
2e for corn seed.
During the corn sorting process, the use of electricity is responsible for 6.00 MtCO
2e of GHG emissions, and consumption of an ear of corn emits 40.85 MtCO
2e of GHG emissions. At this stage, 3.4% is used as a factor for allocating GHG emissions from the cultivation process to corncobs. Lastly, in the pelletizing stage, electricity usage accounts for slightly higher emissions of 6.06 MtCO
2e, and consumption of corncobs is responsible for 1.63 MtCO
2e of GHG emissions. The total emissions calculated using the economic allocation method are 4.08% lower compared to those calculated using the mass allocation method, i.e., when distributing GHG emissions among different products or processes, the economic allocation method (which allocates emissions based on the economic value or revenue of products) results in 4.08% less GHG emissions than when using the mass allocation method (which allocates emissions based on the physical mass of products). Essentially, the way emissions are divided between products based on economic value shows a lower total emissions figure than when divided based on their mass.
Table 6 details the input materials needed for the production of one ton of wood pellets, with the data divided into three categories: cultivation of Para rubber trees, cultivation of fast-growing trees, and production of wood pellets. In the cultivation of Para rubber trees, 2.258 tons of sprout, a minimal amount of fertilizer (0.001 tons), diesel (0.002 L), and electricity (0.013 MWh) are required to produce 0.89 tons of Para rubber logs and 0.11 tons of latex. For fast-growing trees, 6 tons of raw materials, 147 cubic meters of water, 0.21 tons of organic fertilizer, a substantial amount of chemical fertilizer (1837 tons), and significant electricity usage (13 MWh) along with 588 L of diesel are used to yield 0.66 tons of Leucaena logs and 0.34 tons of Acacia logs. The production ratio of fast-growing trees was calculated based on data obtained from the study of Saosee et al. When it comes to the actual production of wood pellets, the input of 1.01 tons of raw materials, 0.75 L of diesel, 0.06 tons of firewood, and 0.02 MWh of electricity results in the creation of one ton of wood pellets, with no dust as a by-product. This table systematically captures the resource inputs against their respective outputs for each step of the wood pellet production process.
Table 7 presents the quantification of a cost analysis for the production of wood pellets. Within the cultivation of Para rubber trees, expenses are incurred for raw materials (THB 794), labor (THB 3021), and electricity (THB 54), leading to outputs of Para rubber logs and latex valued at THB 2500 and 2075, respectively. The cultivation of fast-growing trees incurs costs for raw materials (THB 530.26), electricity (THB 24.35), diesel (THB 8.25), and fertilizer (THB 27.02), which result in outputs of Leucaena and Acacia logs, each valued at THB 800.
For the actual production of wood pellets, costs include raw materials (THB 1197.69), diesel (THB 26.30), firewood (THB 78.13), electricity (THB 36.99), labor (THB 69.20), and operations and maintenance (O&M; THB 120.05). These inputs contribute to the production of wood pellets valued at THB 2136. The table provides an itemized view of costs against the financial value of the outputs in each stage of the wood pellet production process.
Table 8 provides a comprehensive account of GHG emissions from the wood pellet production process, totaling 157.39 MtCO
2e. For the cultivation of Para rubber trees, GHG emissions are calculated from the use of fertilizer (5.74 MtCO
2e), diesel (26.39 MtCO
2e), and electricity (17.28 MtCO
2e), with each emission value derived by applying the respective emission factors to the activity data. In the cultivation of fast-growing trees, electricity, water, diesel, and chemical fertilizer contribute to emissions of 0.42, 3.03, 101.42, and 0.0002 MtCO
2e, respectively.
The production of wood pellets sees further emissions from the use of diesel (0.47 MtCO2e), firewood (0.45 MtCO2e), and electricity (2.19 MtCO2e). The emissions for each input are derived by applying the respective emission factors to the activity data. This comprehensive calculation of total emissions demonstrates the environmental impact of the wood pellet production process, as captured in the table. Considering the total GHG emissions from biomass pellet production (including corn and wood pellets), the overall emissions throughout the process amount to 219.96 MtCO₂e. Each ton of biomass pellets emits 0.7602 tCO₂e.
3.3. Develop an Input–Output Table for Thailand’s Biomass Pellet Sector
The summary table presents monetary data of the items related to the production of biomass pellets as shown in
Table 9.
The biomass pellet sector’s total value amounts to 731.78 mTHB, with its annual operating surplus reaching 13,063 mTHB. Unit cost of biomass pellet is THB 2529 per ton. Monetary data from the preceding activity were classified according to Thailand’s input–output identifier code to align new items obtained from the previous section with an existing sector. A list of economic sectors associated with the production of biomass pellets is shown in
Table 10.
The assumption for selecting the demand industry was based on the payment for energy purchases and the list of industrial sectors that have the potential to use biomass pellets as fuel. It was assumed in this research that biomass pellets could partially replace the consumption of coal, electricity, petroleum, and natural gas. The expenditure on energy consumption by the demand sector was taken into account to calculate the sector’s percentage of energy demand. Consequently, the maximum percentage of the sectors that can consume biomass pellets was applied to estimate the cost of biomass pellets by sector. The breakdown of biomass pellet demand by sector, expressed as percentages, is shown in
Table 11.
Table 11 displays the sectors with high expenditure on energy, including electricity (54.00%), plastic wares (7.59%), cement (7.30%), petroleum and natural gas (5.92%), and spinning (3.97%). The value of the biomass pellets sector was allocated to each industry based on the maximum percentage of biomass pellets that each sector can utilize as an alternative energy source in their processes. The price of biomass pellets by sector is presented in
Table 12.
Symmetric input–output tables for the biomass pellet sector in Thailand were created in accordance with the IOT development principle initiated by EUstat. The sector was structured within the same economic framework as Thailand’s IOTs to ensure that integration of the biomass pellet sector into the existing IOTs is accurate and feasible. The biomass pellet sector comprises 45 × 45 inter-sectoral linkages. Intermediary transactions encompass sectors 002 to 190, representing the flow of goods and services in monetary terms. The value-added sector encompasses sectors 201 to 209, with Sector 210 indicating the total cost of the product inclusive of value-added. Final demand sectors, such as private consumption expenditure, government consumption expenditure, and gross fixed capital formation, are covered from sectors 301 to 309, with sector 310 representing the summation of final demand.